Mold, system and method for manufacturing a molded part

ABSTRACT

A mold, system and method for manufacturing a part includes injection molding a substrate in a single injection mold and optionally trimming the panel substrate. The substrate can have a first configuration or a second, different configuration. Trimming of the substrate can occur when the substrate has the first configuration to define an aperture in the substrate.

BACKGROUND

Injection molded panel substrates are used conventionally in a varietyof applications. One such application is as part of the instrument panelassembly on a vehicle that is arranged with a generally horizontalportion disposed over the instrument panel components of the vehicle(e.g., speedometer, etc.) that extends toward the front windshield.Sometimes, different vehicles and/or vehicle types have such instrumentpanel assemblies and injection molded panel substrates thereforconfigured differently. For example, a base model of a particularvehicle may include a panel substrate configured according to a firstconfiguration and a higher end model of the same vehicle may include asimilar panel substrate but configured according to a secondconfiguration. For example, when the panel substrate is to be a part ofan instrument panel assembly, the base model may include a generallysolid upper portion, whereas the higher end model may include anaperture formed therethrough into which an audio speaker of a vehiclesound system can be accommodated.

Conventionally, separate process lines were needed to form injectionmolded panel substrates having varying designs or configurations. Forexample, a first process line could include a first injection mold forinjection molding the panel substrate according to a first configurationfor use on the base model and a second process line could include asecond injection mold for injection molding the panel substrateaccording to the second configuration for use in the higher end model.

SUMMARY

According to one aspect, a method for manufacturing a panel assembly fora vehicle includes injection molding a panel substrate in a singleinjection mold and trimming the panel substrate. In particular, thepanel substrate can have a first configuration when the panel substrateis for a first vehicle type and the panel substrate can have a second,different configuration when the panel substrate is for a second vehicletype. Trimming of the panel substrate can occur when the panel substratehas the first configuration to define a part aperture in the panelsubstrate.

According to another aspect, a system for manufacturing a panel assemblyfor a vehicle is provided. More particularly, the system according tothis aspect includes an injection mold for injection molding a panelsubstrate with a first configuration when the panel substrate is for afirst vehicle type and a second, different configuration when the panelsubstrate is for a second vehicle type. The system further includes atrimmer for trimming a part aperture into the panel substrate when thepanel substrate has the first configuration for the first vehicle type.

According to still another aspect, a mold capable of molding differentparts includes a first mold surface and a second mold surface positionedopposite the first mold surface. A plurality of recesses on the firstmold surface define a perimeter. The mold further includes a pluralityof fingers each having an outer surface The fingers are movable from afirst position wherein the outer surface of each finger is conformalwith the second mold surface to allow a first part to be molded and asecond position wherein the fingers are extended outward from the secondmold surface and each finger is positioned in one of the recesses alongthe perimeter to allow a second part to be molded that is different thanthe first part.

According to a further aspect, a mold capable of molding different partsincludes a first mold surface and a second mold surface positionedopposite the first mold surface. The mold further includes a pluralityof ridges, a plurality of recesses and a plurality of fingers. Theplurality of ridges extend from the first mold surface toward the secondmold surface and define a perimeter. The ridges are spaced apart todefine gaps therebetween along the perimeter. The plurality of recessesis on the first mold surface with each recess positioned along the moldsurface in the gap disposed between adjacent ones of the ridges. Theplurality of fingers each have an outer surface and the fingers aremovable from a first position wherein the outer surface of each fingeris conformal with the second mold surface to allow a first part to bemolded and a second position wherein the fingers are extended outwardfrom the second mold surface and positioned in the recesses along theperimeter to allow a second part to be molded that is different than thefirst part.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a system for manufacturing apanel assembly for a vehicle according to an exemplary embodiment.

FIG. 2 is a perspective view of a panel assembly having an injectionmolded panel substrate configured for a first vehicle type.

FIG. 2A is an enlarged partial perspective view of the panel assembly ofFIG. 2 showing a trim part (e.g., a speaker cover) mounted to a panelsubstrate over a part aperture defined in the panel substrate.

FIG. 3 is a perspective view of a panel assembly having an injectionmolded panel substrate configured for a second vehicle type.

FIG. 3A is an enlarged partial perspective view of the panel assembly ofFIG. 3 showing a solid area at the location where the trim part ismounted to the panel substrate of FIG. 2A.

FIG. 4 is a partial underside view of the panel substrate of the panelassembly of FIGS. 2 and 2A showing spaced apart thick areas definingcore pin apertures and a trim line recess interconnecting the thickareas.

FIG. 5 is a partial underside view similar to FIG. 4 but of a panelsubstrate of the panel assembly of FIGS. 3 and 3A showing spaced apartthick areas (without core pin apertures) and a trim line recessinterconnecting the thick areas.

FIG. 6 is a schematic view of an injection mold according to anexemplary embodiment.

FIG. 6A is a partial enlarged view of the lower mold half of FIG. 6showing a trim line ridge and recessed areas defined on a moldingsurface of the lower mold half.

FIG. 7 is an underside perspective view of an upper mold half of theinjection mold of FIG. 6.

FIG. 7A is a partial enlarged view of the upper mold half of FIG. 7showing core pins protruding from a molding surface of the upper moldhalf.

FIG. 7B is a view similar to FIG. 7A but showing core pins retractedinto the molding surface of the upper mold half so as to be conformalwith the molding surface.

FIG. 8 is a partial cross-sectional view taken along the line 8-8 ofFIG. 4.

FIG. 9 is a partial cross-sectional view taken along the line 9-9 ofFIG. 4.

FIG. 10 is a view of the panel substrate of FIG. 4 but shown after atrimming operation trims the panel substrate to define the panelaperture therein.

FIG. 11 is an underside perspective view of the trim part (e.g., aspeaker cover) of FIG. 2A.

FIG. 12 is a partial cross-sectional view of the panel assembly of FIGS.2 and 2A taken at the location of one of the core pin apertures.

FIG. 13 is a process flow diagram depicting a method for manufacturing apanel assembly for a vehicle according to an exemplary embodiment.

FIG. 14 is a schematic cross-section view of the injection mold of FIG.6 showing the core pins retracted within the upper mold half.

FIG. 15 is another schematic cross-section view similar of the injectionmold similar to FIG. 14 but showing the core pins extended from theupper mold half and received within recesses defined in a lower moldhalf.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are for purposes ofillustrating one or more exemplary embodiments and not for purposes oflimiting the same, FIG. 1 illustrates a system for manufacturing a panelassembly of a vehicle and is generally designated by reference numeral10. As shown, the system 10 of the illustrated embodiment includes aninjection mold 12, a secondary process station 14 and a trimming station16 (all shown schematically). As will be described in more detail below,the injection mold 12 is a single injection mold capable of injectionmolding a first part and a second part that is different from the firstpart (i.e., capable of molding different parts). The first and secondparts can be panel substrates having varying configurations (e.g., panelsubstrate 18 in FIG. 4 or panel substrate 20 in FIG. 5). Moreparticularly, from this single injection mold 12, the injection moldedpanel substrate can have a first configuration (e.g., panel substrate 18of FIG. 4) when the panel substrate is for a first vehicle type and thepanel substrate can have a second, different configuration (e.g., panelsubstrate 20 of FIG. 5) when the panel substrate is for a second vehicletype. As used herein, vehicle types can represent different vehicles,different vehicle models and/or different model types of the samevehicle model. For example, the first vehicle type could be a base levelor type of a vehicle model and the second, different configuration couldbe a higher end model type of the same vehicle model. Thus, theinjection mold 12 is for injection molding the panel substrate with afirst configuration (FIG. 4) when the panel substrate is for a firstvehicle type and a second, different configuration when the panelsubstrate (FIG. 5) is for a second vehicle type.

The secondary process station 14 can be a skin installer suitable foroptionally forming and then adhering a separate article or skin, such aspad sheet (e.g., pad sheet 22 in FIGS. 2A, 3A and 12), to the panelsubstrate 18 or 20. In one embodiment, as is understood and appreciatedby those skilled in the art, the secondary process station 14 is capableof both forming the pad sheet 22 and adhering the pad sheet 22 to thepanel substrate 18 or 20 molded by the injection mold 12. Alternatively,the secondary process station 14 can be provided with an inventory ofpad sheets formed elsewhere and function only to adhere each pad sheet22 to the panel substrate 18 or 20. As known and understood by thoseskilled in the art, in one embodiment, the pad sheet 22 can be adheredto the panel substrate 18 or 20 via a suitable structural foam. As afurther alternative, the secondary process station 14 can affix theseparate article (e.g., pad sheet 22) to the substrate 18 or 20 via someother affixing method, such as mechanically coupling via suitablemechanical couplers, conjoining via molding, etc.

The trimming station 16 can include a trimmer 24 (e.g., a trim diecutting edge schematically shown in FIG. 8) provided for trimming a partaperture (e.g., part aperture 26 shown in FIG. 10) into panel substrate18 when the panel substrate 18 molded by the injection mold 12 has thefirst configuration for the first vehicle type. In a non-limitingexample, the trimmer 24 may be a hydraulic die including one or moreblades used to trim the part aperture 26. In one embodiment, theinjection mold 12 molds the panel substrate 18, the secondary processstation 14 applies the pad sheet 22 to the panel substrate 18 and thetrimming station 16 trims or cuts away a portion of the panel substrateto define the part aperture 26 therein. When the panel substrate 20 ismolded by the injection mold 12, the panel substrate 20 can bypass thetrimming station 16 to avoid being trimmed. Optionally, the secondaryprocess station 14 and the trimming station 16 can be combined andprovided as a single station on an assembly line. Those skilled in theart will appreciate that the sequence of installing the skin 22 and thetrimming of the part aperture 26 can be reversed if so desired so thatthe part aperture 26 is first cut and then the pad sheet 22 is appliedto the panel substrate 18.

FIGS. 2, 2A, 3 and 3A illustrate panel assemblies that can be formed bythe system 10 of FIG. 1. More particularly, FIG. 2 illustrates a panelassembly 30 that can have the panel substrate 18 injection molded withthe first configuration and FIG. 3 illustrates a panel assembly 34 thatcan have the panel substrate 20 injection molded with the secondconfiguration. With additional reference to FIG. 2A, a portion of thepanel assembly 30 is shown including the panel substrate 18, skin 22 anda trim part 32. In the illustrated embodiment, the trim part 32 isconfigured as a speaker cover, though this is not required and the trimpart 32 could be some other type of trim part. With additional referenceto 3A, a portion of the panel assembly 34 is shown including the panelsubstrate 20 and skin 22. The panel assembly 34 does not include a trimpart such as trim part 32 and is generally solid and/or contiguous atthe location at which the trim part 32 is provided on the panel assembly30. As will be described in more detail below, the panel assemblies 30and 34 can be produced by the same system 10 of FIG. 1 via the injectionmold 12, which is a single injection mold, together with the secondaryprocess station 14 and the trimming station 16 for the panel assemblies30.

FIG. 4 shows the panel substrate 18, and particularly an underside 18 athereof, corresponding generally to the portion of the panel substrate18 shown in FIG. 2A. As described above, the panel substrate 18 isprovided by the injection mold 12 as having the first configuration fora first vehicle type. As shown, the underside 18 a of the panelsubstrate 18 includes optionally a trim line recess 18 b, optionally aplurality of thick portions or areas 18 c defined in spaced apartrelation to one another along and interrupting the trim line recess 18b, and a plurality of core pin apertures 40. When thick areas 18 c areprovided, the core pin apertures 40 may be positioned in each of theplurality of thick areas 18 c. When the trim line recess 18 b ispresent, the trim line recess 18 b may define or be defined at thelocation of a predetermined trim line 42 (shown schematically in FIG. 4and not actually appearing in the panel substrate 18) along which thepanel substrate 18 will be trimmed in the trimming station 16.Therefore, it is to be understood that the core pin apertures 40 may beapplied without either the thick areas 18 c or the trim line recess 18b, the core pin apertures 40 may be applied with the trim line recess 18b but without the thick areas 18 c, the core pin apertures 40 may beapplied with the thick areas 18 c but without the trim line recess 18 b,or the core pin apertures 40 may be applied with both the trim linerecess 18 b and the thick areas 18 c.

FIG. 5 shows the panel substrate 20, and particularly an underside 20 athereof, corresponding generally to the portion of the panel substrate20 shown in FIG. 3A. As described above, the panel substrate 20 isprovided by the injection mold 12 as having the second configuration fora second vehicle type. Like the panel substrate 18, the underside 20 aof the panel substrate 20 may include an optional trim line recess 20 band an optional plurality of the thick portions or areas 20 c defined inspaced relation to one another along and interrupting the trim linerecess 20 b. There are no core pin apertures (e.g., core pin apertures40 of the panel substrate 18) defined in the thick areas 20 c of thepanel substrate 20. In all other respects, the trim line recess 20 b andthe thick areas 20 c can be identical to the trim line recess 18 b andthe thick areas 18 c on the panel substrate 18.

With reference now to FIG. 6, the injection mold 12 is shown in moredetail but still schematically. The mold 12 includes a lower or firstmold half 50 having a molding surface or lower side 52 and an upper orsecond mold half 54. The lower side can be curved to thereby provide acurved panel substrate 18 or 20. With additional reference to FIG. 7,which shows the upper mold half 54 removed from the mold 12, the uppermold half 54 has a molding surface or upper side 56. The lower side 52defines a lower side of a mold cavity in the injection mold 12 and formsthe underside of the injection molded panel substrate (i.e., the sides18 a and 20 a of the panel substrate shown in FIGS. 4 and 5). Likewise,the upper side 56 defines an upper side of the mold cavity in the mold12 and forms the upper side of the injection molded panel substrate(i.e., the sides revealed in FIGS. 2A and 3A). The upper side 56 can bea textured or contoured surface (not shown) that defines the upper sides18 d, 20 d of the panel substrates 18, 20 as textured or contouredsurfaces (see texturing 44 in FIG. 3A, for example).

With reference to FIG. 6A, which shows an enlarged portion of the lowerside 52 that forms both the optional trim line recess 18 b or 20 b andthe optional thick portions 18 c and 20 c when molding the substrates18, 20, the lower side 52 can include a trim line ridge 58 protrudingfrom the lower side 52 toward the upper side 56 and a plurality ofrecessed areas 60 (also referred to herein as recesses) spaced apartfrom one another and defined along the trim line ridge 58 so as tointerrupt or form gaps in the trim line ridge 58. Each of the trim lineridge 58 and the plurality of recesses 60 define a perimeter, at leastpartially. As shown, the trim line ridge 58 extends between andinterconnects the recessed areas 60 to define the perimeter. In theillustrated embodiment, the recessed areas 60 are generally rectangularshaped depressions have relatively flat bottoms 60 a, though thisconfiguration is not required. For sake of clarity, these mold features(i.e., the trim line ridge 58 and the recessed areas 60) are not shownin FIG. 6. The recessed areas 60 interrupt the trim line ridge 58thereby defining the trim line ridge 58 as a plurality of spaced parttrim line ridge portions 58 a that define the perimeter. Accordingly,the ridge portions 58 a are spaced apart from one another to define gapstherebetween along the perimeter. The recessed areas 60 are disposedrespectively in these gaps defined between adjacent ones of the ridgeportions 58 a.

With additional reference to FIGS. 7A and 7B, which shows an enlargedportion of the upper side 56 that is opposite the portion of the lowerside 52 shown in FIG. 6A, the injection mold 12 includes a plurality offingers or core pins 62 that are movable or extendable into the moldcavity from the upper side 56 of the upper mold half 54. Moreparticularly, and with further reference to FIGS. 14 and 15, each of thecore pins 62 is moveable between a first or retracted position (shown inFIGS. 7B and 14) wherein each core pin 62 is removed from the moldcavity of the injection mold 12 and a second or extended position (shownin FIGS. 7A and 15) wherein each core pin 62 protrudes into the moldcavity. Each of the core pins 62 is spaced apart on the upper side 56 ofthe upper mold half 54 and is relatively positioned in alignment withthe recessed areas 60 on the lower mold half 50. The core pins 62 eachhave a generally flat distal or outer surface 62 a that can mate insealing engagement with the flat bottoms 60 a of the recessed areas 60on the lower side 52.

These flat distal surfaces 62 a can be conformal with the upper side 56when the core pins 62 are retracted to define a portion of the moldcavity (as shown in FIGS. 7B and 14). That is, the distal surface 62 aof each core pin 62 can be conformal with the upper side or moldingsurface 56 of the upper mold 54 when the core pins 62 are in theretracted position to allow the panel substrate 20 to be molded by themold 12 and the core pins 62 can extend outward from the upper side ormolding surface 56 of the upper mold 54 when the core pins 62 are in theextended position to allow the panel substrate 18 to be molded by themold 12. Additionally, each core pin 62 can be positioned in acorresponding one of the recessed areas 60 of the lower side 52 definedalong the perimeter. In particular, the core pins 62 can engage thelower side 52 of the lower mold 50, and particularly engage the flatbottoms 60 a of the recesses 60, when the core pins 62 are in theextended position.

In operation, as shown in FIG. 15, the core pins 62 are each in theextended position and received in the recessed areas 60 of the lowerside 52 to complete the perimeter partially formed by the trim lineridge 58 when the panel substrate is molded with the first configuration(i.e., panel substrate 18 of FIG. 4). Accordingly, the core pins 62define the core pin apertures 40 in the panel substrate 18. As shown inFIG. 4, the core pin apertures 40 are spaced apart along the trim linerecess 18 b (and thus along the predetermined trim line) to, ultimatelyafter trimming, define the part aperture 26 of FIG. 10 together with aportion of the trim line recess 20 b that remains after trimming. Incontrast, as shown in FIG. 14, the core pins 62 are each in theretracted position when the panel substrate is molded with the secondconfiguration (i.e., panel substrate 20 of FIG. 5). Accordingly, no pinapertures 40 are formed when the core pins 62 are in the retractedposition.

Also, because the core pins 62 can be conformal with the upper side 56when retracted to form the panel substrate 20, the panel substrate 20corresponds to an entirety of the mold cavity of the mold 12 and isgenerally molded as if the core pins 62 are not present. There can be,however, some evidence of the core pins 62 on the upper side 20 d of thepanel substrate (e.g., footprints or mold artifacts showing on themolded part, not shown).

The recessed areas 60 can advantageously function to allow the core pins62 to be moved by a single actuator (e.g., one hydraulic cylinder, notshown) even when the molded parts (i.e., substrates 18 and 20) havecurved configurations. More particular, the core pins 62 may all move asame distance (e.g., a stroke distance) between the retracted positionand the extended position when a single actuator is used. To enable eachof the core pins 62 to engage and/or mate with the lower side 52 when inthe extended position, the recessed areas 60 can be provided at varyingdepths relative to one another. Accordingly, when a single actuator isused, each of the plurality of core pins 62 travels from the retractedposition to the extended position along parallel paths and each fingertravels the same distance. The recessed areas 60 function to accommodatethe core pins 62 in such an arrangement. Alternatively, multipleactuators can be used so that the core pins 62 can travel alongnon-parallel paths and/or at different stroke lengths.

In both panel substrates 18, 20, the trim line ridge 58 (when present)in the lower side 52 of the lower mold half 50 forms a trim line recess(trim line recess 18 b in the panel substrate 18 and trim line recess 20b in the panel substrate 20). Only the trim line recess 18 b is furtherused, as only the panel substrate 18 undergoes trimming at the trimmingstation 16. However, as part of being able to mold both panel substrates18 and 20 on a single mold 12, the trim line recess 20 b is formed inthe panel substrate 20, though it is not further used. With additionalreference to FIG. 8, a cross-section of the trim line recess 18 b on thepanel substrate 18 is shown. As mentioned above, the trim line recess 18b is located on the panel substrate 18 to correspond to thepredetermined trim line 42 (FIG. 4). The predetermined trim line 42represents the location on the panel substrate 18 at which the trimmer24 (shown only schematically in FIG. 8) of the trimming station 16 willtrim the panel substrate 18 and thus also defines at least a partialperimeter of the part aperture 26. As shown in FIG. 8, the trim linerecess 18 b is an area of reduced thickness relative to adjacent areasof the panel substrate 18, which enables easier trimming of the partaperture 26 into the panel substrate 18. In the illustrated embodiment,an inner wall 18 e of the trim line recess 18 b can have a more gradualtaper (e.g., 1.5 degrees) relative to an outer wall 18 f of the trimline recess 18 b to enable easier removal of the panel substrate 18 (andlikewise of the panel substrate 20) after molding, though this is notrequired and other specific configurations could be employed. Withreference to FIG. 9, a cross-section is shown through one of the thickareas 20 c and the corresponding core pin aperture 40

FIG. 10 shows the panel substrate 18, and particularly the underside 18a thereof, after the panel substrate 18 undergoes trimming at thetrimming station 16. As shown, a portion of the trim line recess 18 bremains and portions of the thick areas 18 c remain. In particular,those portions of the trim line recess 18 b and the thick areas 18 cthat reside outside the predetermined trim line 42 (FIG. 4) remain aftertrimming at the trimming station 16. Also, portions 40 a of the core pinapertures 40 residing outside the predetermined trim line 42 remainafter trimming. This is achieved by the relative positioning of the corepins 62 relative to the predetermined trim line 42. That is, one or moreof the core pins 62 is arranged relative to the predetermined trim line42 so that the portions 40 a remain after trimming. One or more of theseremaining portions 40 a of the core pin apertures 40 can serve as cliprecesses for assisting in affixing or securing the trim part 32 to thepanel substrate 18. For example, with additional reference to FIG. 11,clips 32 a defined on an underside of the trim part 32 can be receivedin the remaining portions 40 a of the core pin apertures 40 to clip thetrim part to the panel substrate 18.

Using the system 10 described hereinabove, a panel assembly (e.g., panelassembly 30 or panel assembly 34) for a vehicle can be manufactured. Thepanel assembly can include a panel substrate (e.g., panel substrate 18or panel substrate 20) formed by injection molding on the injection mold12. The panel substrate has a first side (e.g., the upper side 18 drevealed in FIG. 2A and the upper side 20 d revealed in FIG. 3A) formedby the upper side 56 of the upper mold half 54 and a second, oppositeside (i.e., the undersides 18 a and 20 a shown respectively in FIGS. 4and 5) formed by the lower side 52 of the lower mold half 50. The panelassembly further includes one of: core pin apertures 40 defined throughthe panel substrate 18 along a predetermined trim line 42 or no core pinapertures 40 defined through the panel substrate 20. A trim line recess18 b or 20 b can also be defined in the panel substrate 18 or 20 alongthe predetermined trim line 42. More particularly, when the panelsubstrate is the panel substrate 18 having the first configuration thepanel substrate 18 can have both core pin apertures 40 and the trim linerecess 18 b as shown in FIG. 4. When the panel substrate is the panelsubstrate 20 having the second configuration, the panel substrate 20 isformed without the core pin apertures 40 but still can have the trimline recess 20 b, though this will not be used as the panel substrate 20does not get trimmed.

The panel assembly, whether panel substrate 18 or panel substrate 20,optionally includes the skin 22 attached to the first side of the panelsubstrate (i.e., the upper sides 18 a and 20 a). The skin 22 can beapplied at the secondary process station 14. In one embodiment, the skin22 is applied via a foam adhesive. When the panel assembly includes thepanel substrate 18, the part aperture 26 can be trimmed into the panelsubstrate 18 by the trimmer 24 of the trimming station 16. As alreadydescribed, trimming occurs along the predetermined trim line 42 andresults in the part aperture 26 being defined through the panelsubstrate 18 as shown in FIG. 10. Additionally, the remaining portions40 a of the core pin apertures 40 (i.e., the portions that remain aftertrimming of the panel substrate 18) can function to assist in clippingthe trim part 32 to the panel substrate 18.

When the panel assembly includes the panel substrate 18, the panelassembly additionally may include the trim part 32, which can be in theform of a speaker cover as shown in the illustrated embodiment in FIGS.2 and 2A, though this is not required. With reference to FIGS. 11 and12, the trim part 32 may have integrally molded clips 32 a received intothe remaining portions 40 a of the core pin aperture of the panelsubstrate 18.

With reference now to FIG. 13, a method for manufacturing a panelassembly for a vehicle will now be described. In particular, the methodwill be described in association with the mold 12 and optionally therest of the system 10 described hereinabove, though it is to beappreciated by those skilled in the art that the method could be usedwith other systems and/or the system 10 configured alternately. As shownin FIG. 13, the method includes, at 100, injection molding a panelsubstrate in a single injection mold. That is, the single injection mold12 can selectively injection mold the panel substrate 18 having a firstconfiguration when the panel substrate 18 is for a first vehicle type orthe panel substrate 20 when the panel substrate 20 has a second,different configuration when the panel substrate 20 is for a secondvehicle type.

Injection molding of the panel substrate 18 includes molding the panelsubstrate 18 with the first configuration with the plurality of corepins 62 each in the extended positions (the positions shown in FIG. 7A),while molding the panel substrate 20 with the second configurationoccurs with the plurality of core pins 62 each in the retracted position(as shown in FIG. 7B). As already described herein, injection moldingthe panel substrate 18 with the first configuration with the pluralityof core pins 62 in the extended position defines the core pin apertures40 in the panel substrate 18. The core pin apertures 40 are spaced apartalong the predetermined trim line 42 which can be at least partiallydefined by the trim line ridge 58 extending from the lower side 52 ofthe lower mold half 50. As also already described, each of the pluralityof core pins 62 corresponds to one of the pin apertures 40 defined inthe panel substrate 18.

Thus, when the panel substrate 18 is injection molded, the core pins 62can function to define the pin apertures 40 through the panel substrate18. In contrast, when the panel substrate 20 is injection molded withthe core pins 62 in the retracted position, no pin apertures 40 aredefined on the panel substrate 20. A trim line recess 18 b or 20 b canbe defined in both of the panel substrates 18 and 20, though it is onlyused for trimming on the panel substrate 18. The injection molding ofthe panel substrate in 100 can optionally include molding a textured orcontoured surface on the first side of the panel substrate. This isaccomplished by providing a textured or contoured upper side 56 of theupper mold half 54 of the injection mold 12. By dispersing the core pins62 and using a plurality of core pins, any un-textured portion of thepanel substrate 20 formed by the flat distal surfaces 62 a of the corepins 62 comprises a relatively small portion of the panel substrate 20and are not concentrated in a single area of the panel substrate 20.

Next, as shown at 102, the skin 22 can be attached to the panelsubstrate 18 or 20 on a first side of the panel substrate (upper side 18d or upper side 20 d). The skin 22 generally can adhere or attach bestto the panel substrate 18 or 20 when the surface to which the skin 22 isdirectly attached is textured or contoured. Accordingly, it isadvantageous to have the largest possible area of the upper sides 18 aor 20 a of the substrates 18 or 20 textured or contoured. When the panelsubstrate 18 is injection molded, substantially an entirety of the upperside of the panel substrate 18 can be contoured or textured so goodadherence of the skin 22 can occur. In a non-limiting example, when thepanel substrate 20 is injection molded, all but the portion of the panelsubstrate 20 formed on the flat distal surfaces 62 a of the core pins 62are contoured or textured. Since the core pins 62 are distributed (i.e.,not concentrated) and form a relatively small portion of the upper sideof the panel substrate 20, good adherence of the skin 22 can also occuron the panel substrate 20. Such good adherence might not occur ininstances where a larger portion and/or more concentrated portions ofnon-textured or flat areas results (e.g., if a single large core pin orslide were used to injection mold the part aperture 26).

Next, at 104, the panel substrate can be trimmed when the panelsubstrate has the first configuration (i.e., when the panel substrate 18is injection molded at 100) to define the part aperture 26 in the panelsubstrate 18. In contrast, when the panel substrate 20 is injectionmolded at 100, no trimming of the panel substrate 20 is necessary. Themolding of the trim line recess 18 b into the underside of the panelsubstrate 18 can aid in trimming of the part aperture 26 as reducedforce is needed to trim the trim line recess 18 b due to it being formedas a thinned section of the panel substrate 18. The trim line recess 20b is also present in the panel substrate 20 but is not used for trimmingand is on the underside of the panel substrate 20 thereby not presentingaesthetic or other issues. Trimming at 104 includes trimming via thetrimmer 24 at the predetermined trim line 42. By the arrangement of thecore pins 62 on the upper side 56 relative to the trim line ridge 58 onthe lower side 52, each pin aperture 40 can be formed so that theremaining portions 40 a after trimming define one or more clip recesses.

When the panel substrate 18 is molded at 100 and the part aperture 26 istrimmed into the panel substrate 18 at 102, a trim part 32, which in theillustrated embodiment is a speaker cover, can next be installed intothe part aperture 26. The clips 32 a of the trim part 32 can beaccommodated in the portions 40 a defined in the panel substrate 18.

Advantages of the above described system 10 and corresponding methodinclude the provision of a system and method that produces a panelassembly adapted for use on varying vehicle types. The use of theplurality of spaced apart core pins 48 along the trim line minimizes thenon-textured surface area on the molded substrate which improvesadherence of the skin 22 to the panel substrate. A further advantage isthe trim line provided on the underside of the panel substrate to enabletrimming of the panel substrate when the panel substrate is to beconfigured as panel substrate 18 for a first vehicle type. Additionally,the plurality of core pins 48 mold the pin apertures 40 in recessedrelation relative to the part aperture 26 so as to enable clip recessesto be formed to enable the trim part 32 to more easily clip to thesubstrate.

It will be appreciated that various of the above-disclosed and otherfeatures and functions, or alternatives or varieties thereof, may bedesirably combined into many other different systems or applications.Also that various presently unforeseen or unanticipated alternatives,modifications, variations or improvements therein may be subsequentlymade by those skilled in the art which are also intended to beencompassed by the following claims.

1. A method for manufacturing a panel assembly for a vehicle,comprising: injection molding a panel substrate in a single injectionmold, wherein the panel substrate has a first configuration when thepanel substrate is for a first vehicle type and the panel substrate hasa second, different configuration when the panel substrate is for asecond vehicle type; and trimming the panel substrate when the panelsubstrate has the first configuration to define a part aperture in thepanel substrate.
 2. The method of claim 1 wherein the panel substrateincludes a first side and a second, opposite side, and further whereininjection molding the panel substrate includes molding a texturedsurface on the first side, the method further including: attaching askin to the panel substrate on the first side of the panel substrate. 3.The method of claim 1 wherein the single injection mold includes aplurality of core pins, each of the plurality of core pins is movablebetween a retracted position wherein each of the plurality of core pinsis removed from a mold cavity of the single injection mold in which thepanel substrate is formed and an extended position wherein each of theplurality of the core pins extends into the mold cavity in which thepanel substrate is formed, and further wherein injection molding thepanel substrate includes molding the panel substrate with the firstconfiguration with the plurality of core pins each in the extendedposition and molding the panel substrate with the second configurationwith the plurality of core pins each in the retracted position.
 4. Themethod of claim 3 wherein injection molding the panel substrate with thefirst configuration with the plurality of core pins in the extendedposition defines core pin apertures in the panel substrate spaced apartalong a predetermined trim line, each of the plurality of core pinscorresponds to one of the plurality of core pin apertures defined in thepanel substrate.
 5. The method of claim 4 wherein trimming the panelincludes trimming at the predetermined trim line with a trim die cuttingedge.
 6. The method of claim 5 wherein each core pin aperture arepositioned relative to the predetermined trim line so that portions ofthe core pin apertures remain in the panel substrate after trimming. 7.The method of claim 5 wherein injection molding the panel substrateincludes molding a trim line recess along the predetermined trim linewith a reduced thickness relative to adjacent areas of the panelsubstrate.
 8. The method of claim 3 wherein the panel substrate includesa first side and a second, opposite side, wherein injection molding thepanel substrate includes molding a textured surface on substantially anentirety of the first side.
 9. The method of claim 1 wherein injectionmolding the panel substrate includes injection molding a trim linerecess of reduced thickness into the panel substrate, the trim linerecess defining a perimeter of the part aperture.
 10. The method ofclaim 9 wherein injection molding the panel substrate with the firstconfiguration includes positioning core pins in extended positions todefine core pin apertures, the core pin apertures spaced apart along theperimeter defined by the trim line recess.
 11. The method of claim 1further including: installing a trim part into the part aperture whenthe panel substrate has the first configuration.
 12. A system formanufacturing a panel assembly for a vehicle, comprising: an injectionmold for injection molding a panel substrate with a first configurationwhen the panel substrate is for a first vehicle type and a second,different configuration when the panel substrate is for a second vehicletype; and a trimmer for trimming a part aperture into the panelsubstrate when the panel substrate has the first configuration for thefirst vehicle type.
 13. The system of claim 12 further including a skininstaller for attaching a skin to the panel substrate.
 14. The system ofclaim 12 wherein the injection mold includes core pins each movablebetween a retracted position wherein each core pin is removed from amold cavity of the injection mold and an extended position wherein eachcore pin protrudes into the mold cavity, the core pins each in theextended position when the panel substrate is molded with the firstconfiguration to define core pin apertures into the panel substrate. 15.The system of claim 14 wherein the pin apertures are spaced apart alonga trim line recess defined in the panel substrate by the injection moldto define the part aperture.
 16. The system of claim 15 wherein each pinaperture is positioned relative to the trim line recess so that aportion of pin aperture remains defined in the panel substrate after thepart aperture is trimmed from the panel substrate.
 17. The system ofclaim 15 wherein the injection mold includes a ridge protruding into themold cavity to define the trim line recess, the trim line recess beingan area of reduced thickness relative to adjacent areas of the panelsubstrate for enabling easier trimming of the part aperture.
 18. A moldcapable of molding different parts, comprising: a first mold surface; asecond mold surface positioned opposite the first mold surface; aplurality of trim line ridge portions extending from the first moldsurface toward the second mold surface and defining a perimeter, theridge portions spaced apart to define gaps therebetween along theperimeter; and a plurality of fingers each having an outer surface, thefingers movable from a first position wherein the outer surface of eachfinger is conformal with the second mold surface to allow a first partto be molded and a second position wherein the fingers are extendedoutward from the second mold surface and positioned in the gaps alongthe perimeter to allow a second part to be molded that is different thanthe first part.
 19. The mold of claim 18 wherein the outer surface ofthe fingers engages the first mold surface when the fingers are in thesecond position.
 20. A mold capable of molding different parts,comprising: a first mold surface; a second mold surface positionedopposite the first mold surface; a plurality of recesses on the firstmold surface defining a perimeter; and a plurality of fingers eachhaving an outer surface, the fingers movable from a first positionwherein the outer surface of each finger is conformal with the secondmold surface to allow a first part to be molded and a second positionwherein the fingers are extended outward from the second mold surfaceand each finger is positioned in one of the recesses along the perimeterto allow a second part to be molded that is different than the firstpart.
 21. The mold of claim 20, wherein the first mold surface iscurved.
 22. The mold of claim 20, wherein the plurality of fingerstravel from the first position to the second position along parallelpaths, and each finger travels the same distance from the first positionto the second position.
 23. A mold capable of molding different parts,comprising: a first mold surface; a second mold surface positionedopposite the first mold surface; a plurality of ridge portions extendingfrom the first mold surface toward the second mold surface and defininga perimeter, the ridges spaced apart to define gaps therebetween alongthe perimeter; a plurality of recesses on the first mold surface witheach recess positioned along the mold surface in the gap disposedbetween adjacent ones of the ridges; and a plurality of fingers eachhaving an outer surface, the fingers movable from a first positionwherein the outer surface of each finger is conformal with the secondmold surface to allow a first part to be molded and a second positionwherein the fingers are extended outward from the second mold surfaceand positioned in the recesses along the perimeter to allow a secondpart to be molded that is different than the first part.